Flame retardant veneer panel

ABSTRACT

A veneer panel may include a face veneer, a first inner layer bonded to the face veneer, a second inner layer bonded to the first inner layer, and a thermally conductive layer bonded to the second inner layer. The first inner layer and the second inner layer are treated with a flame retardant. The first inner layer is disposed between the face veneer and the second inner layer, and the second inner layer is disposed between the first inner layer and the thermally conductive layer.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 63/085,036, filed on Sep. 29, 2020, the disclosure of which is incorporated herein by reference in its entirety.

TECHNOLOGY

The present disclosure relates to decorative and structural panels, and, more specifically, to fire-resistant panels.

BACKGROUND

Various veneer panels are used in aircraft. Certain veneer panels may be susceptible to tearing, wrinkling, and curling. Further, veneer panels may experience delamination in some applications. In other instances, the veneer panels may not be useable in vehicular applications due to other limitations such as conformance with flammability regulations.

SUMMARY

A veneer panel includes, a face veneer, a first inner layer bonded to the face veneer, a second inner layer bonded to the first inner layer, the first inner layer and the second inner layer are treated with a flame retardant, and a thermally conductive layer bonded to the second inner layer wherein the thermally conductive layer is disposed between the first inner layer and the second inner layer.

The veneer panel can also include a first adhesive material disposed between the face veneer and the first inner layer, wherein the first adhesive material bonds the first inner layer to a back surface of the face veneer. A second adhesive material can be disposed between the thermally conductive layer and the second inner layer, wherein the second adhesive material bonds the first inner layer to the thermally conductive layer and bonds the second inner layer to the thermally conductive layer. The first adhesive material can include a phenolic adhesive and the second adhesive material comprises an acrylic adhesive. The phenolic adhesive can be a dry film phenolic adhesive.

The thermally conductive layer can include an annealed aluminum. A thickness of the first adhesive material can be between 0.001 inches and 0.01 inches and more specifically 0.002 inches and 0.007 inches inclusive (i.e., between 0.0508 mm and 0.1778 mm). A thickness of the second adhesive material can be between 0.001 inches and 0.01 inches and more specifically 0.001 inches and 0.01 inches inclusive (i.e., between 0.0254 mm and 0.254 mm).

A thickness of the thermally conductive layer can be between 0.001 inches and 0.040 inches, and more specifically between 0.001 inches and 0.020 inches inclusive (i.e., between 0.0254 mm and 0.508 mm). A thickness of the face veneer can be between 0.016 inches and 0.024 inches inclusive (i.e., from 0.4064 mm to 0.6096 mm). A thickness of the first inner layer can be between 0.016 inches and 0.024 inches inclusive (i.e., between 0.4064 mm and 0.6096 mm). A thickness of the second inner layer can be between 0.016 inches and 0.024 inches inclusive (i.e., between 0.4064 mm and 0.6096 mm).

The second inner layer can be a backing layer. The face veneer can include a wood. A combination of the first inner layer, the second inner layer, and the thermally conductive layer can be treated with a fire retardant solution. wherein the fire retardant solution can include bromide, and wherein the face veneer is not treated with a flame retardant.

A method of manufacturing a veneer panel, is also disclosed. The method include stacking a second adhesive material between a first inner layer and a thermally conductive layer and between a second inner layer and the thermally conductive layer, stacking a first inner layer, a second inner layer, and a thermally conductive layer, applying heat and pressure to the first inner layer, the adhesive material, the second inner layer, and the thermally conductive layer to create a first stack, treating the first stack with a chemical bath, stacking a face veneer and the first stack, disposing a first adhesive material between the first stack and the face veneer, and applying heat and pressure to the face veneer and the first stack.

The foregoing features and elements may be combined in various combinations without exclusivity, unless expressly indicated otherwise. These features and elements as well as the operation thereof will become more apparent in light of the following description and the accompanying drawings. It should be understood, however, the following description and drawings are intended to be exemplary in nature and non-limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter of the present disclosure is particularly pointed out and distinctly claimed in the concluding portion of the specification. A more complete understanding of the present disclosure, however, may best be obtained by referring to the detailed description and claims when considered in connection with the figures, wherein like numerals denote like elements.

FIG. 1 illustrates an aircraft interior including various elements comprising veneer panels, in accordance with various embodiments;

FIGS. 2A and 2B illustrate an assembly view and a cross sectional view, respectively, of an inner panel for incorporation into veneer panels, in accordance with various embodiments;

FIG. 2C illustrates a cross section view of the inner panel of FIG. 2B after being chemically treated with a flame retardant, in accordance with various embodiments;

FIGS. 2D and 2E illustrate an assembly view and a cross sectional view, respectively, of a veneer panel including a face veneer layer, a chemically treated inner panel, in accordance with various embodiments; and

FIG. 3 illustrates a flow diagram of a method of making a four-ply veneer panel, according to various embodiments.

DETAILED DESCRIPTION

The detailed description of exemplary embodiments herein makes reference to the accompanying drawings, which show exemplary embodiments by way of illustration. While these exemplary embodiments are described in sufficient detail to enable those skilled in the art to practice the exemplary embodiments of the disclosure, it should be understood that other embodiments may be realized and that logical changes and adaptations in design and construction may be made in accordance with this disclosure and the teachings herein. Thus, the detailed description herein is presented for purposes of illustration only and not limitation. The steps recited in any of the method or process descriptions may be executed in any order and are not necessarily limited to the order presented.

Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Also, any reference to attached, fixed, connected or the like may include permanent, removable, temporary, partial, full and/or any other possible attachment option. Additionally, any reference to without contact (or similar phrases) may also include reduced contact or minimal contact. Surface shading lines may be used throughout the figures to denote different parts but not necessarily to denote the same or different materials.

It should be appreciated that considerable benefits will be realized for the safety of passengers and crew in aircraft flying throughout the world to provide a flame resistant wood veneer panel for the construction of aviation interior structures which meets the stringent vertical flammability requirements of Federal Aviation Requirement (FAR) 25.853, which is part of the Title 14 of the Code of Federal Regulations (CFR), issued by the Federal Aviation Administration (FAA), such as the present four-ply flame retardant veneer panel system discussed in greater detail hereinafter.

Referring now to FIG. 1 , an aircraft interior 10 including various elements comprising aviation veneer panels 100 is shown, in accordance with various embodiments. Aviation veneer panels 100 may include four-ply veneer panels, as described below, mounted or otherwise coupled to a substrate (e.g., cabinetry, tables, chairs, hand rails, etc.).

Referring now to FIGS. 2A-2D, a flame retardant veneer panel system 101 maybe formed by first forming a first stack 102 comprising a first fire-treated inner layer 130 a (also referred to herein as a first inner layer) and a second fire-treated inner layer 130 b (also referred to herein as a second inner layer). First inner layer 130 a includes a first surface 131 a and a second surface 132 a opposite first surface 131 a. First inner layer 130 a may comprise a thin layer of poplar wood, or other wood species. In various embodiments, a thickness T2 of first inner layer 130 a extending from first surface 131 a to second surface 132 a may be between 0.016 inches and 0.024 inches (i.e., between 0.4064 mm and 0.6096 mm). In various embodiments, T2 may be between 0.017 inches and 0.023 inches (i.e., between 0.4318 mm and 0.5842 mm). In various embodiments, T2 may be between 0.018 inches and 0.022 inches (i.e., between 0.4572 mm and 0.5588 mm).

Second inner layer 130 b may be similar to first inner layer 130 a. In this regard, second inner layer 130 b includes a first surface 131 b and a second surface 132 b opposite first surface 131 b. Second inner layer 130 b may comprise a thin layer of poplar wood, or other wood species. In various embodiments, a thickness T5 of second inner layer 130 b extending from first surface 131 b to second surface 131 b may be between 0.016 inches and 0.024 inches (i.e., between 0.4064 mm and 0.6096 mm). In various embodiments, T5 may be between 0.017 inches and 0.023 inches (i.e., between 0.4318 mm and 0.5842 mm). In various embodiments, T5 may be between 0.018 inches and 0.022 inches (i.e., between 0.4572 mm and 0.5588 mm).

In various embodiments, a wood grain of first inner layer 130 a is oriented in a first direction, such as the X-direction for example, and a wood grain of second inner layer 130 b is oriented in a second direction, such as the Y direction for example. In this manner, the wood grains of first inner layer 130 a and second inner layer 130 b are oriented perpendicular to one another to create a tension-balanced panel 102 once the first inner layer 130 a and second inner layer 130 b are cured together via an adhesive material 135 (also referred to herein as a third adhesive).

A thermally conductive layer 150 is placed between the first inner layer 130 a and the second inner layer 130 b. Thermally conductive layer 150 may comprise a material having a thermally conductivity of 40 W/m·K or greater. In various embodiments, thermally conductive layer 150 comprises a metal. Thermally conductive layer 150 may comprise one or more layers of aluminum or an aluminum alloy. In various embodiments, thermally conductive layer 150 comprises a thin sheet of annealed aluminum. In various embodiments, thermally conductive layer 150 may comprise an aluminum foil layer. Thermally conductive layer 150 includes a first surface 151 and a second surface 152 opposite first surface 151. In various embodiments, a thickness T5 of thermally conductive layer 150 extending from first surface 151 to second surface 152 may be between 0.001 inches and 0.040 inches, more specifically, 0.001 inches and 0.020 inches (i.e., between 0.0254 mm and 0.508 mm). In various embodiments, T5 may be between 0.005 inches and 0.020 inches (i.e., between 0.127 mm and 0.508 mm).

In various embodiments, adhesive material 116 comprises a flame-retardant acrylic adhesive. In various embodiments, adhesive material 116 may be in the form of a thermoset adhesive, such as a dry film acrylic adhesive. A dry film acrylic adhesive may allow adhesive material 116 to be cut in a sheet form and disposed between thermally conductive layer 150 each of the inner layers 130 a and 130 b. In various embodiments, a thickness T7 of adhesive material 116 extending from a first surface 163 of adhesive material 116 to a second surface 164 of adhesive material 116 may be between 0.001 inches and 0.01 inches (i.e., between 0.0254 mm and 0.254 mm).

With reference to FIG. 2B, a heat and/or pressure treatment of the first stack 102 (e.g., pressing the first stack 102 inside a press machine) is illustrated, in accordance with various embodiments. Pressure P may be a compressive force applied uniformly and/or substantially uniformly across the outer surfaces of the first stack 102 through first inner layer 130 a and second inner layer 130 b. the first stack 102 may also be heated to reach a thermal threshold necessary to cure the adhesive material 116 to bond inner layers 130 a and 120 b to thermally conductive layer.

With reference to FIG. 2C, the first stack 102 may be treated with a flame retardant 145 for fire protection. Flame retardant 145 may comprise a bromide solution. In this regard flame retardant 145 may be a brominated flame retardant. Other flame retardants contemplated herein include halogenic chemicals, phosphates, acids, chitosan, boric acid, ammonium borates, ammonium polyphosphate, melamine, borates, silicates, organic silicone, zinc borates, metal hydroxides, sulfonates, graphite or graphene, intumescence, sodium hex metaphosphate, polyethylenimine, among others.

In various embodiments, the first stack 102 is soaked with the flame retardant 145. In various embodiments, the flame retardant 145 is brushed or rolled onto the first stack 102. In various embodiments, the first stack 102 is placed into a bath of the flame retardant 145 for a pre-determined duration. The flame retardant 145 may be absorbed into the first stack 102. The flame retardant 145 is carried by the first stack 102. In response to being burned, for example during a fire, the flame retardant 145—which is infused in the first stack 102—emits a gas to suffocate the flames and extinguish the fire. In this regard, flame retardant 145 may act as a gas phase flame retardant by forming a blanket of noncombustible gasses around the flame front. In various embodiments, the first stack 102 is sanded down to a desired thickness after being treated with the flame retardant 145.

With combined reference to FIG. 2D and FIG. 2E, four-ply flame retardant veneer panel system 101 is further formed by adding a face veneer layer 110 to the first stack 102. Face veneer layer 110 may comprise a thin layer of wood, such as walnut, cherry, birch, rosewood, oak, maple, mahogany, hemlock, teak, walnut, or other wood species. Face veneer layer 110 may be manufactured from most wood species, common and exotic alike. Face veneer layer 110 may also be a manufactured product comprising one or more natural wood(s) and/or synthetic materials, referred to herein as “composite wood.” Face veneer layer 110 may include a first surface 111 (also referred to as a face surface) and a second surface 112 (also referred to as a back surface) opposite first surface 111. Back surface 112 of face veneer layer 110 may be oriented toward thermally conductive layer 150. In various embodiments, first surface 111 of face veneer layer 110 may be sanded to provide a smooth, decorative surface for finishing. In various embodiments, a thickness T1 of face veneer layer 110 extending from first surface 111 to second surface 112 may be between 0.005 inches and 0.030 inches and more specifically between 0.005 inches and 0.030 inches and more specifically 0.016 inches and 0.024 inches (i.e., from 0.4064 mm to 0.6096 mm). In various embodiments, face veneer layer 110 is not treated with a flame retardant. However, face veneer layer 110 may be treated with a flame retardant, in accordance with various embodiments.

In various embodiments, an adhesive material 115 (also referred to herein as a first adhesive material) may be applied between face veneer layer 110 and first inner layer 130 a. In various embodiments, adhesive material 115 comprises a phenolic resin. In various embodiments, adhesive material 115 comprises a vinyl-phenolic resin. In various embodiments, adhesive material 115 may be in the form of a thermoset adhesive, such as a dry film phenolic adhesive. A dry film phenolic adhesive may allow adhesive material 115 to be cut in a sheet form and disposed between second surface 112 of face veneer layer 110 and first surface 131 a of first inner layer 130 a during the layup process. In various embodiments, a thickness T6 of adhesive material 115 extending from a first surface 161 of adhesive material 115 to a second surface 162 of adhesive material 115 may be between 0.002 inches and 0.007 inches (i.e., between 0.0508 mm and 0.1778 mm).

With momentary reference to FIG. 2E, a heat and/or pressure treatment of veneer panel system 101 (e.g., pressing veneer panel system 101 inside a press machine) is illustrated, in accordance with various embodiments. Pressure P may be a compressive force applied uniformly and/or substantially uniformly across the outer surfaces of veneer panel system 101 through face veneer layer 110, first inner layer 130 a, second inner layer 130 b, and thermally conductive layer 150. Veneer panel system 101 may also be heated to reach a thermal threshold necessary to cure the adhesive material 115 to bond first inner layer 130 a. For example, the adhesive material 115 may wet second surface 112 of face veneer layer 110 and first surface 131 a of first inner layer 130 a.

Veneer panel system 101 may be formed in any dimensions, and may readily be made into rectangular 4 foot by 8 foot (i.e., 1.2 m by 2.4 m) panels. Veneer panel system 101 may also be cut into smaller sizes or varied shapes, depending on the substrate (e.g., cabinet, table, rail, etc.) to which veneer panel system 101 may be mounted.

Veneer panel system 101 may be configured to address fire retardancy on two fronts: first, by releasing noncombustible gasses from the flame retardant solution (i.e., flame retardant 145) of two-ply panel 102 that extinguishes the flames, and second, by drawing heat away from the flame, via thermally conductive layer 150, to extinguish the flame. Veneer panel system 101 may comply with FAR 25.853. FIG. 3 , shows a step-by step a method 300 of making a veneer panel 101 described above.

Benefits and other advantages have been described herein with regard to specific embodiments. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. However, the benefits, advantages, and any elements that may cause any benefit or advantage to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the disclosure. The scope of the disclosure is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” Moreover, where a phrase similar to “at least one of A, B, or C” is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B and C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C.

Systems, methods and apparatus are provided herein. In the detailed description herein, references to “various embodiments”, “one embodiment”, “an embodiment”, “an example embodiment”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments.

Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is intended to invoke 35 U.S.C. 112(f), unless the element is expressly recited using the phrase “means for.” As used herein, the terms “comprises”, “comprising”, or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. 

What is claimed is:
 1. A veneer panel, comprising: a face veneer; a first inner layer of a first material bonded to the face veneer; a first adhesive material disposed between the face veneer and the first inner layer, wherein the first adhesive material bonds the first inner layer to a back surface of the face veneer; a second inner layer of the first material bonded to the first inner layer, wherein the first inner layer and the second inner layer are treated with a flame retardant; a thermally conductive layer of a second material different from the first material bonded to the second inner layer, wherein the thermally conductive layer is disposed between the first inner layer and the second inner layer, wherein the thermally conductive layer is treated with a flame retardant; a second adhesive material disposed between the first inner layer and the thermally conductive layer, wherein the second adhesive material bonds the first inner layer to the thermally conductive layer; and a third adhesive material disposed between the thermally conductive layer and the second inner layer, wherein the third adhesive material bonds the thermally conductive layer to the second inner layer.
 2. The veneer panel of claim 1, wherein the first adhesive material comprises a phenolic adhesive and the second adhesive material comprises an acrylic adhesive.
 3. The veneer panel of claim 2, wherein the phenolic adhesive is a dry film phenolic adhesive.
 4. The veneer panel of claim 1, wherein the thermally conductive layer comprises an annealed aluminum.
 5. The veneer panel of claim 1, wherein a thickness of the first adhesive material is between 0.001 inches and 0.01 inches inclusive.
 6. The veneer panel of claim 1, wherein a thickness of the second adhesive material is between 0.001 inches and 0.01 inches inclusive (between 0.0254 mm and 0.254 mm).
 7. The veneer panel of claim 1, wherein a thickness of the thermally conductive layer is between 0.001 inches and 0.040 inches inclusive.
 8. The veneer panel of claim 1, wherein a thickness of the face veneer is between 0.005 inches and 0.030 inches inclusive.
 9. The veneer panel of claim 1, wherein a thickness of the first inner layer is between 0.016 inches and 0.024 inches inclusive (between 0.4064 mm and 0.6096 mm).
 10. The veneer panel of claim 8, wherein a thickness of the second inner layer is between 0.016 inches and 0.024 inches inclusive (between 0.4064 mm and 0.6096 mm).
 11. The veneer panel of claim 1, wherein the second inner layer is a backing layer.
 12. The veneer panel of claim 1, wherein the face veneer includes a wood.
 13. The veneer panel of claim 1, wherein the flame retardant includes a fire retardant solution that includes bromide.
 14. The veneer panel of claim 1, wherein the face veneer is not treated with a flame retardant.
 15. The veneer panel of claim 1, wherein the first material has a lower thermal conductivity than the second material.
 16. The veneer panel of claim 1, wherein the first material is wood and wherein the second material is metallic. 